Note: Descriptions are shown in the official language in which they were submitted.
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CABLE CONNECTOR SYSTEM
FIELD OF THE INVENTION
[001] The present invention relates to cable connector system. More
specifically, the
cable connector system is insulated and includes lockable contact assemblies
for safe and
efficient power distribution.
BACKGROUND OF THE INVENTION
[002] Conventional power cables are typically plugged into a panel for power
distribution systems. For example, portable power generation systems include
large shipping
container-like units that contain power generation equipment and supply power
to moveable oil
drilling rigs. Problems often occur in such distribution systems with
installation errors due to
mis-tightening of connections. Often those connections become loose. Also,
electrically
charged surfaces of such systems are often exposed. Additionally, the cables
of those
conventional systems are rigidly connected to the panels and thus have no
freedom of movement.
[003] Therefore, a need exists for safe and efficient power distribution that
reduces
installation errors and costs.
SUMMARY OF THE INVENTION
[004] Accordingly, the present invention provides a cable connector system
that
comprises a first contact assembly that includes a housing and a first contact
that is received in
the housing. The first contact has a cable termination portion that is
configured to terminate a
cable at an end thereof and an interface portion that includes a first contact
surface and a cap at
an end thereof. The cap has a first locking surface. A second contact assembly
mates with the
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first contact assembly and includes a housing and a second contact received in
the housing. The
second contact has a second contact surface that is configured to engage the
first contact surface
of the first contact assembly and the second contact is rotatable with respect
to the first contact of
the first contact assembly. A locking member that includes a second locking
surface is
configured to engage the first locking surface of the cap, wherein when the
second locking
surface engages the first locking surface, the first contact assembly is
prevented from moving
axially with respect to the second contact assembly while the first contact
remains rotatable with
respect to the second contact.
[005] The present invention may also provide a cable connector system that
comprises a
first contact assembly that includes a housing, a first conductive contact
that is received in the
housing, and a receiving area that is defined between the housing and the
first conductive
contact. The housing is insulative. The first conductive contact has a cable
termination portion
configured to terminate a cable at an end thereof and an interface portion
that includes a first
contact surface and a cap at an end thereof. The cap is insulative. A second
contact assembly
mates with the first contact assembly. The second contact assembly includes an
outer housing
and a second conductive contact that is received in the outer housing. The
outer housing is
insulative. The second conductive contact has a second contact surface that is
configured to
engage the first contact surface of the first contact assembly that defines an
electrical path
therebetween. An insulative plug is configured to be received in the second
contact assembly
when the second contact assembly is not mated with the first contact assembly,
wherein when the
first and second contact assemblies are mated, the housing of the first
contact assembly covers all
exposed surfaces of the second conductive contact and the outer housing of the
second contact
assembly covers all exposed surfaces of the first conductive contact, and
wherein when the first
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and second contact assemblies are unmated, the cap and the housing of the
first contact assembly
covers all exposed surfaces of the first conductive contact and the outer
housing of the second
contact assembly and the insulative plug cover all exposed surfaces of the
second conductive
contact.
[006] The present invention may further provide a cable connector system that
comprises a plurality of first contact assemblies. Each of the first contact
assemblies includes a
first contact that has a cable termination portion configured to terminate a
cable at an end thereof
and an interface portion that includes a first contact surface and a cap at an
end thereof. The cap
has a first locking surface. A plurality of second contact assemblies are
mateable with the first
contact assemblies. Each of the second contact assemblies includes a second
contact that has a
second contact surface that is configured to engage the first contact
surfaces, respectively. Each
of the second contacts is rotatable with respect to each of the first
contacts. A housing block
supports the second contact assemblies. A locking member that includes a
second locking
surface is configured to engage the first locking surfaces of the first
contact assemblies, wherein
when the second locking surface engages each of the first locking surfaces,
each of the first
contact assemblies is prevented from moving axially with respect to each of
the second contact
assemblies while each of the first contacts remain rotatable with each of the
second contacts.
[007] Other objects, advantages and salient features of the invention will
become
apparent from the following detailed description, which, taken in conjunction
with the annexed
drawings, discloses a preferred embodiment of the present invention.
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BRIEF DESCRIPTION OF THE DRAWINGS
[008] A more complete appreciation of the invention and many of the attendant
advantages thereof will be readily obtained as the same becomes better
understood by reference
to the following detailed description when considered in connection with the
accompanying
drawings, wherein:
[009] Figure 1 is a perspective view of a cable connector system according to
an
exemplary embodiment of the invention, showing a plurality of socket contact
assemblies that
mate with a plurality of plug contact assemblies;
[0010] Figure 2 is a front plan view of the plurality of socket contact
assemblies
illustrated in Figure 1;
[0011] Figure 3 is a perspective view of one of the plurality of plug contact
assemblies
illustrated in Figure 1;
[0012] Figure 4 is a cross-sectional view of the plug contact assembly
illustrated in
Figure 3;
[0013] Figure 5 is a perspective view of a block housing of one of the
plurality of socket
contact assemblies illustrated in Figure 1;
[0014] Figure 6 is a side elevational view of the block housing illustrated in
Figure 5,
showing a partial cross-sectional view of a socket;
[0015] Figure 7 is a perspective view of an outer housing of one of the
plurality of socket
contact assemblies illustrated in Figure 1;
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[0016] Figure 8 is a front elevational view of the outer housing illustrated
in Figure 7;
[0017] Figure 9 is a perspective view of a locking member of the cable
connector system
illustrated in Figure 1;
[0018] Figure 10 is a side elevational view of the locking member illustrated
in Figure 9;
and
[0019] Figure 11 is a partial cross-sectional view of one of the plurality of
plug contact
assemblies illustrated in Figure 1 mated with one of the plurality of socket
contact assemblies
illustrated in Figure 1.
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DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0010] Referring to Figures 1-11, a cable connector system 100 in accordance
with an
exemplary embodiment of the present invention generally comprises one or more
pin contact
assemblies 110 that are adapted to mate with one or more socket contact
assemblies 130. The
cable connector system 100 may be used, for example, to provide safe and
efficient power
distribution, such as in power generation systems and the like. Both the pin
contact assemblies
110 and the socket contact assemblies 130 are preferably electrically
insulated such that no
conductive surfaces are exposed, thereby preventing contact, accidental or
otherwise, with
electrically powered surfaces or contacts. The cable connector system 100
preferably also
includes one or more locking members 160 to prevent loosening or separation of
the mated pin
contact and socket contact assemblies 110 and 130 to ensure proper electrical
contact
therebetween. The invention can be used anywhere a power connection is
required, a quick
connect and disconnect would be beneficial; positive locking is needed; a
degree of freedom that
allows the cable to position itself rotationally, minimizing internal cable
torsion is needed; and
efficient carrying of increased electrical loads is needed. The system 100 of
the present
invention reduces installation errors due to mis-tightening of the connection.
That in turn reduces
installation costs, particularly when the equipment moves around from location
to location,
country, state, or worksite.
[0011] As seen in Figures 1 and 2, the socket contact assemblies 130 are
preferably
mounted to an insulative panel 180 that may be in turn be mounted to an
electrical panel (not
shown) for power distribution. The pin contact assemblies 110 each terminate
individual power
cables (not shown). The pin and socket contact assemblies 110 and 130 are
designed to mate
such that the system is electrically insulated to avoid contact with
conductive surfaces. The
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socket contact assemblies 130 are preferably grouped together, such as in
groups of three, as
seen in Figure 1; however the system may include a single socket contact
assembly 130 that
mates with a single pin contact assembly 110.
[0012] Figures 3 and 4 illustrate an exemplary pin contact assembly 110 in
accordance
with the present invention. The pin contact assembly 110 generally includes a
contact 112, a
main housing 114, and a cap 116. The contact 112 may have a cable termination
portion 118 and
an interface portion 120. The cable termination portion 118 is designed to
terminate a cable (not
shown) in any known manner. The interface portion 120 preferably has the shape
of a pin that
has an outer contact surface 122 configured to engage a contact of a mating
socket contact
assembly 130, thereby creating an electrical path therebetween.
[0013] The main housing 114 generally supports and covers the interface
portion 120 of
the contact 112. A secondary cover 124 (Figure 1) may be used to cover the
cable termination
portion 118 of the contact 112. The main housing 114 may be attached to the
contact 112 by a
threaded engagement 126 or by any other known attachment. A receiving area 128
is defined
between the main housing 114 and the contact 112 that is adapted to receive a
portion of the
socket contact assembly 130.
[0014] The cap 116 is disposed at the end of the interface portion 120, as
best seen in
Figure 4. The cap 116 includes opposing ends 170 and 172 where one end 170 is
coupled to the
interface portion 120 at the end thereof, such as by a threaded engagement 174
or other known
engagement. The other end 172 of the cap 116 is sized to be received in the
mating socket
contact assembly 130 and includes a locking surface 176 that may be in the
form of an annular
groove.
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[0015] Both the main housing 114 and the cap 116 are formed of a insulative
material.
The insulative main housing 114 covers the outer contact surface 122 of the
conductive contact
112 and the insulative cap 116 is disposed on and covers the end of the
contact 112 such that any
exposed surfaces of the contact 112 are covered by an insulative material or
member.
[0016] Figures 5 and 6 illustrate one or more socket contact assemblies 130
being
supported by a housing block 140. Each socket contact assembly 130 includes a
contact 132 that
is preferably a socket. As best seen in Figure 6, the socket 132 may be a
radially resilient barrel
with an internal hollow cylindrical sleeve or contact surface 134 adapted to
receive and engage
the contact 112 of the mating pin contact assembly 110. The socket 132 is
designed to allow for
increased electrical loads. The hollow sleeve 134 may be formed by adding
contactor strips to
the inside of the barrel, as described in commonly owned U.S. Patent No.
4,734,063, herein
incorporated by reference. The contactor strips provide a continuous
electrical connection with
the inserted pin contact 112, while permitting the pin contact 112 to rotate
with respect to the
socket contact 132.
[0017] The housing block 140 is preferably conductive and generally has three
sections
including a socket supporting section 142, a panel section 144, and a mid-
section 146
therebetween. The socket supporting section 142 has an inner bore 148 that
receives the socket
contact 132 and an open end 150 that receives the mating pin contact 112. The
panel section 144
is a flat member extending from the mid-section 146 that extends through the
insulative panel
180, as seen in Figure 1. The mid-section 146 has a secondary bore 152 that is
continuous with
the inner bore 148 of the supporting section 142 and is sized to receive the
cap 116 of the mating
pin contact assembly 110. The mid-section 146 is preferably wider than the
panel section 144 to
act as a stop against the insulative panel 180. The mid-section 146 may also
include a
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passageway 154 (Figure 5) that is adapted to receive the locking member 160.
Although the
housing block 140 is shown as grouping together more than one socket contact
assembly 130, the
housing block 140 may be configured to support a single socket contact
assembly 130.
[0018] An insulative outer housing 156 (Figures 7 and 8) may surround the
housing
block 140. The outer housing 156 preferably includes one or more access
openings 158 that
correspond to the open ends 150 of the socket supporting section 142,
respectively, for receiving
the mating pin contacts 112. The outer housing 156 may include one or more
insulative plugs
190 tied thereto such that when the pin contacts 112 are not received in the
socket contacts 132,
the insulative plugs 190 can be inserted into the respective access openings
158, through the
open ends 150, and into the socket contacts 132, so that the plugs 190 in
combination with the
insulative outer housing 156, cover all exposed conductive surfaces.
[0019] Figures 9 and 10 illustrate an exemplary locking member 160 in
accordance with
the present invention. The locking member 160 generally includes a stem 162
and a lever 164.
The stem 162 preferably includes an outer locking surface 166 adapted to
engage the locking
surface 176 of the cap 116 when the pin and socket contact assemblies 110 and
130 are mated.
The stem 162 may include one or more undercuts 168 for releasing the locking
member 160
from a locked position upon rotation of the lever 164. Each undercut 168 is
preferably arranged
such that the longitudinal length of the lever 164 is substantially
perpendicular to the longitudinal
lengths of the undercuts 168 such that rotating the lever locks and releases
the locking member
160. The stem 162 is configured to be received in the passageway 154 of the
housing block 140.
[0020] As seen in Figure 11, when the pin contact assembly 110 is mated with
the socket
contact assembly 130, the pin contact 112 is received in the socket contact
132 such that the
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contact surfaces 122 and 134 engage, thereby forming an electrical path
between the assemblies.
The socket supporting section 142 of the housing block 140 is accepted in the
receiving area 128
of the pin contact assembly 110 and the outer housing 156 of the socket
contact assembly 130
surrounds the main housing 114 of the pin contact assembly 110. The insulative
cap 116 of the
pin contact assembly 110 is inserted into the secondary bore 152 of the
housing block 140.
[0021] When the pin and contact assemblies 110 and 130 are mated, they may be
locked
together by the locking member 160 such that the pin contact assembly 110
cannot be pulled
axially out of the socket contact assembly 130. In particular, the outer
locking surface 166 of the
locking member 160 engages the locking surface 176 of the cap 116 in an
interference fit, as
seen in Figure 11. That is the stem 162 of the locking member 160 is received
in the annular
groove 176 in an interference fit. The locking member 160, however, does not
prevent the pin
contact assembly 110 from rotating with respect to the socket contact assembly
130. To release
the locking member 160, the lever 164 of the locking member 160 is rotated
until the undercut
168 of the locking member 160 reaches the groove 176 of the cap 116, thereby
disengaging the
interference fit therebetween.
[0022] As seen in Figures 1 and 2, one locking member 160 may be used to lock
multiple
pin and socket contact assemblies 110 and 130. In that case, the number of
undercuts 168 on the
stem 162 of the locking member 160 should equal the number of pin or socket
contact
assemblies to provide a release mechanism for each. Also, it is preferable
that several groups of
pin and contact assemblies 110 and 130 be mounted to the insulative panel 180
for a higher
density of cable connections, as seen in Figure 1. However, the system of the
present invention
may include a single pin contact assembly 110 mated to a single socket contact
assembly 130
that are mounted to the panel 180.
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[0023] When mated, all conductive surfaces of the pin and socket contact
assemblies 110
and 130 are preferably covered by an insulative member. More specifically, the
pin contact 122
is covered not only by the main housing 114 and the cap 116 but also by the
outer housing 156 of
the socket contact assembly 130. And the socket contact 132 is covered by the
main housing 114
of the pin contact assembly 110 and by the outer housing 156. When the pin and
contact
assemblies 110 and 130 are not mated, the cap 116 and the main housing 114
cover the surfaces
of the pin contact 112 and the outer housing 156 of the socket contact
assembly 130 and along
with the insulative plug 190 cover all exposed surfaces of the socket contact
132.
[0024] While particular embodiments have been chosen to illustrate the
invention, it will
be understood by those skilled in the art that various changes and
modifications can be made
therein without departing from the scope of the invention as defined in the
appended claims.
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